Dual orifice nozzle and method for internally coating containers

ABSTRACT

A nozzle, nozzle assembly and method for internally coating containers uses a dual orifice nozzle and method to direct divergent distinct spray patterns at separate interior surface portions of the container where the coating liquid is required most. The nozzle comprises a generally cylindrical body having a forward portion, a middle portion, a rear portion, a first conduit passageway extending longitudinally therethrough terminating in a first opening disposed in the forward portion, and a second conduit passageway extending longitudinally therethrough terminating in a second opening formed in the forward portion of the nozzle body. The first and second conduit passageways direct the separate sprays of coating liquid generally forward of the nozzle body in separate distinct patterns diverging from one another with an acute included angle. The conduits are suited to receive airless nozzle inserts that direct the separate spray patterns at the distinct interior portions to thereby define a dual orifice nozzle assembly. In the internal coating method, a flow of coating liquid is divided into distinct first and second flow portions, with the first flow portion being directed toward one interior surface portion of the container and the second flow portion being directed toward a second interior surface portion of the container.

This is a continuation-in-part application of U.S. patent applicationSer. No. 07/597,251, filed Oct. 15, 1990, now U.S. Pat. No. 5,096,746.

TECHNICAL FIELD

This invention relates to systems and methods for internally coatingcontainers, and more particularly relates to a dual orifice nozzleassembly and method for directing separate spray patterns at offsetangles to coat distinct interior surfaces of a container.

BACKGROUND OF THE INVENTION

A method of metal container manufacture in current use by the metalcontainer industry is the two-piece can process. This process involvesforming a drawn cup from a metal sheet and then deep drawing the cupinto a can configuration. After the can body is completely configuratedand decorated, but before the end is assembled onto the body, theinterior surface of the can body is coated with a protective coating ofa synthetic resin material.

It is conventional practice to apply, as the coating material, a heathardenable resin dispersed in an aqueous medium which is sprayed intothe interior walls of the container. The open-ended can is caused to bepassed through an internal coating station, commonly referred to as a"coating tunnel," where the coating liquid is sprayed into the interiorof the can to coat its internal surface. The wet-coated container isthen passed through an oven in which hot air is circulated to evaporatethe aqueous medium and harden the coating.

In some conventional systems, the coating is sprayed into the interiorof the container while the container is inverted in an upright positionon a reticulated belt. In such systems, as the containers travel throughthe coating tunnel, the interior surface walls of the containers arecontacted with an aqueous dispersion of a coating resin by sprayingmeans, usually comprising a plurality of single orifice nozzles disposedunder and along the reticulated belt, which direct a sequence of wideatomized sprays of wet resin coating onto the interior walls.

Substantially all the conventional nozzles used in such applications areof the single orifice type which make controlling the application of thecoating to the interior surface difficult, especially near the open endof the container.

The airless nozzle most commonly used today in such applicationsincludes an internal, hemispherical passage termination which is cutthrough by an external, V-shaped groove to form an elongated,elliptical-like orifice. Liquid material pumped at high pressuresthrough such a spray nozzle is forced by the hemispherical terminationof the passageway to converge in its flow at and through the elongatedorifice. Because of the converging flow at the orifice, the liquidmaterial is expelled through the orifice into a planar, expanding,fan-like film which breaks into spray particles which are carried bytheir momentum to the article target.

In the prior art, it was common during container manufacturingoperations to simply excessively coat the interior of a container sothat the "hard-to-reach" areas would receive a sufficiently thick layerof coating deposited thereon. This, naturally, left an excessively thicklayer of coating in the "easy-to-reach" areas of the container. Oneattempt to cure this problem is disclosed by Stumphauzer, U.S. Pat. No.3,697,313. The procedure of Stumphauzer results in a substantiallyuniform coating being applied over the interior surface of the sidewallof the container.

A further attempt to remedy this problem is disclosed by Rehman, U.S.Pat. No. 4,378,386. Rehman relates to a method and apparatus forapplying a uniform coating to the interior surface of a containerutilizing at least two nozzle means to apply the coating material. Oneof the nozzle means is operative to spray the lower portion of thecylindrical sidewall of the container while the other nozzle means isoperative to spray the top portion of the sidewall and the crown orcenter section of the bottom wall. Rehman is especially intended for usewith high solids or higher solids liquid coating materials. It is aspecific object of Rehman to achieve a very even and uniform coating ofthe interior of the container.

Such prior systems are commonly plagued by excessive overspray andnozzle misting, each of which is costly due to the coating liquid thatis wasted during such operations. It is more cost efficient to placemore coating liquid on the interior areas where it is required most,that is, near the top and/or the bottom, particularly the bottom, of thecontainer and less on the middle of the sidewall of the container as thetop of the container is worked upon during the necking operation and thebottom of the container is in contact with the pin tip of the pin chain.The middle sidewall normally has minimal contact and consequently needsless coating.

Thus, there has developed in the metallic container manufacturingindustry a need for an internal coating nozzle assembly capable ofplacing the coating where it is most required within the interior of thecontainer, while also minimizing the amount of wasted coating liquidnormally produced by an internal coating operation.

SUMMARY OF THE INVENTION

This invention presents a dual orifice nozzle assembly, device andmethod which forms two distinct and separate spray patterns offset atacute angles to spray or coat a specific interior area of a containerwith each respective pattern. An object of this invention is to providethe capability of more efficiently directing coating where it isrequired most inside the container while minimizing nozzle misting andoverspray, thereby decreasing the amount of wasted coating liquidnormally generated by the internal coating operation.

Generally, a preferred spray nozzle presented by the invention comprisesa generally cylindrical body having a forward portion, a middle portion,a rear portion, a first conduit passageway extending longitudinallytherethrough terminating in a first opening formed in the forwardportion, and a second conduit passageway extending longitudinallytherethrough terminating in a second opening formed in the forwardportion of the body. The first and second openings, and preferably thepassageways, are each oriented at an acute angle of approximately 20degrees with respect to a central longitudinal axis of the nozzle bodyto accept spray forming means to direct separate sprays of coatingliquid forwardly of the body and generally in separate patternsdiverging from the central longitudinal axis of the nozzle. The middleportion of the nozzle body is generally cylindrical in shape and issmaller in diameter than the rear portion of the nozzle body, which isdefined by a circular shoulder portion having a recessed cavity formedtherein.

The first and second openings of the forward portion of the nozzle bodyare generally circular in shape and equally spaced on opposite sides ofthe central longitudinal axis. The first opening is preferably formed ina first planar surface which is substantially perpendicular to alongitudinal axis of the first conduit passageway, and the secondopening is preferably formed in a second planar surface which issubstantially perpendicular to a longitudinal axis of the second conduitpassageway. The first planar surface of the forward portion of thenozzle body is disposed at an obtuse angle with respect to the secondplanar surface.

At their openings, each of the first and second conduit passageways hasa beveled portion adjacent the forward portion of the nozzle body, asmall diameter cylindrical portion adjacent the rear portion of thenozzle body, a large diameter cylindrical portion juxtaposed the beveledportion and an internally threaded portion interposed between thebeveled portion and the large diameter cylindrical portion.

In use, the spray nozzle of the invention is intended to be arrangedwith respect to a container to be sprayed so that the longitudinal axisof the nozzle body is disposed at an acute angle in relation to acentral longitudinal axis of the container.

In a preferred method of this invention, the first spray forming meansof the nozzle body forms the first flow into a first spray pattern anddirects the first spray pattern at a first interior portion of thecontainer, which is preferably an area adjacent the open end of thecontainer, and the second spray forming means of the nozzle body formsthe second flow into a second spray pattern and directs the second spraypattern at a second interior portion of the container, which ispreferably an area adjacent the closed end of the container.

The spray nozzle assembly, device and method presented by a preferredembodiment of this invention directs substantially all of the coatingliquid onto the interior surface of the container where it is mosteffective and minimizes nozzle misting and overspray, thus decreasingwasted coating liquid. The direction of the first and second separatespray patterns near the closed end and the open end of the containerresults in a film deposited on the interior surface of the containerhaving a greater thickness adjacent the ends thereof.

An alternative preferred embodiment of this invention provides a spraynozzle similar to the above-described spray nozzle except that the firstpassageway extends longitudinally through the spray nozzle substantiallyparallel to the central longitudinal axis of the nozzle body and thesecond passageway is oriented at an acute angle of approximately 26-29degrees with respect to the central longitudinal axis. Both first andsecond passageways are adapted to accept spray forming means to directseparate sprays of coating liquid forwardly of the body and generally inseparate diverging patterns. This alternative spray nozzle embodimentemploys a lesser included angle between the first and second passagewaysto better facilitate the coating of the entire interior surface of thecontainer with one pass of the container spray by the nozzle assembly inthe coating tunnel.

Thus, an alternative preferred spray nozzle presented by the inventioncomprises a generally cylindrical body having a forward portion, amiddle portion, a rear portion, a first conduit passageway extendinglongitudinally therethrough terminating in a first opening formed in theforward portion, and a second conduit passageway extendinglongitudinally therethrough terminating in a second opening formed inthe forward portion of the body. The first opening, and preferably itscorresponding passageway, is oriented substantially parallel withrespect to a central longitudinal axis of the nozzle body. The secondopening, and preferably its corresponding passageway, is oriented at anacute angle with respect to the central longitudinal axis of the nozzlebody. Both openings are adapted to accept spray forming means to directseparate sprays of coating liquid forwardly of the body and generally inseparate patterns diverging from one another.

The first and second openings of the forward portion of the nozzle bodyare generally circular in shape, but unlike the first embodiment, areunequally spaced on opposite sides of the central longitudinal axis ofthe nozzle. The first opening is preferably formed in a first planarsurface which is substantially perpendicular to a longitudinal axis ofthe first conduit passageway, and the second opening is preferablyformed in a second planar surface which is substantially perpendicularto a longitudinal axis of the second conduit passageway. The firstplanar surface is disposed substantially horizontally whereas the secondplanar surface is disposed at an obtuse angle with respect to the firstplanar surface.

In substantially all other aspects, the alternative embodiments of thespray nozzle are similar. The middle portions of their nozzle bodies aresimilarly generally cylindrical in shape and are smaller in diameterthan the rear portions of the nozzle bodies, which are defined bycircular shoulder portions having recessed cavities formed therein. Attheir openings, each of the first and second conduit passageways of thespray nozzles also diverge at acute angles and terminate at a beveledportion adjacent the forward portions of the nozzle bodies. Each of thespray nozzles also has a small diameter cylindrical portion adjacent therear portions of the nozzle bodies, large diameter cylindrical portionsjuxtaposed to the beveled portions and internally threaded portionsinterposed between the beveled portions and the large diametercylindrical portions.

In use, the alternative spray nozzle of the invention is intended to bearranged with respect to a container to be sprayed so that thelongitudinal axis of the nozzle body is offset laterally of the centrallongitudinal axis of the container and at an acute angle ofapproximately 3-5 degrees.

In an alternative preferred method provided by this invention, the firstspray forming means of the alternative nozzle body forms the first flowinto a first spray pattern and directs the first spray pattern at afirst interior portion of the container, which is preferably an areacomprising the sidewall of the container and a portion of the crown orcenter section of the bottom wall, and the second spray forming meansforms the second flow into a second spray pattern and directs the secondspray pattern at a second interior portion of the container, which ispreferably approximately the lower half portion of the sidewall adjacentto the closed end of the container.

The spray nozzle assembly, device and method presented by thealternative preferred embodiment of this invention directs substantiallyall of the coating liquid onto the interior surface of the containerwhere it is most effective and minimizes nozzle misting and overspray,thus decreasing wasted coating liquid. The direction of the first andsecond separate spray patterns results in a film deposited on theinterior surface of the container having a greater thickness adjacent tothe closed end of the container, where coating is most desired.

The spray nozzles of this invention are adapted to threadably receive afirst nozzle insert within the first conduit passageway adjacent theforward portion of the nozzle body for directing a first spray patterngenerally toward a first interior portion of the container. Likewise,the second conduit passageway of the nozzle body is adapted tothreadably receive a second nozzle insert adjacent the forward portionof the nozzle body for directing a second spray pattern generally towarda second interior portion of the container. Being received in the firstan second conduit passageways, the first and second inserts and theirlongitudinal axes of the first preferred embodiment concomitantly lie atacute angles with respect to the central longitudinal axis of thenozzle. In the alternative preferred embodiment of the spray nozzleassembly, the first insert and its longitudinal axis lie substantiallyparallel to the central axis of the container, whereas the second insertand its longitudinal axis lie at an acute angle with respect to thecentral axis.

The spray forming means suitable for use with this invention arepreferably generally cylindrical "airless" nozzle inserts having anexternally threaded portion to allow them to be threadably received inthe internally threaded portions of the first and second conduitpassageways. The nozzle inserts act to form a fan-like spray pattern ofthe coating liquid as it is dispersed.

Thus, the invention provides a nozzle assembly, device and method thatdirects the internal coating liquid more accurately in two sprays whoseaxes diverge at an acute angle to deposit the coating liquid where it ismost required inside the container, thereby reducing the amount ofcoating liquid required in the internal coating process. The inventionreduces nozzle misting and overspray, which results in a reduction ofman hours spent on cleaning the machines and this naturally increasesthe efficiency of the manufacturing process. Further, the nozzleassembly and device of this invention is less likely to blister than areconventional devices.

Further features of the invention will be apparent from the followingdrawings and disclosure of preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of the operating arrangement of a nozzle assemblyfor internal coating applications according to a preferred embodiment ofthis invention;

FIG. 2 is a cross-sectional view of a preferred embodiment of a spraynozzle, without nozzle inserts, provided by the invention taken alongplane 2--2 of FIG. 3;

FIG. 3 is a top view of the spray nozzle of FIG. 2;

FIG. 4 is an enlarged, isolated partial cross-sectional view of one ofthe conduit passageways of the spray nozzle of FIG. 2;

FIGS. 5A and 5B present graphical illustrations of the film thicknesscomparison achieved by a preferred embodiment of this invention;

FIG. 6 is a plan view of the operating arrangement of a nozzle assemblyfor internal coating applications according to an alternative preferredembodiment of this invention;

FIG. 7 is a cross-sectional view of an alternative preferred embodimentof a spray nozzle, without nozzle inserts, provided by the inventiontaken along plane 7--7 of FIG. 8;

FIG. 8 is a top view of the spray nozzle of FIG. 7; and

FIG. 9 is an enlarged, isolated, partial cross-sectional view of thefirst conduit passageway of the spray nozzle of FIG. 7.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE FORCARRYING OUT THE INVENTION

A preferred embodiment of this invention, including a spray nozzle 50,nozzle assembly 10 and a method of use presented by this invention, isshown and will be discussed in reference to FIGS. 1-4, wherein likereference numerals correspond to like components. An alternativepreferred embodiment of this invention will be discussed hereinbelow inreference to FIGS. 6-9.

Referring now to FIG. 1, nozzle assembly 10 is intended to be arrangedadjacent a container 25 as it is transported along in the manufactureprocess and includes nozzle 50 and nozzle inserts 12 and 14. Container25 has a generally cylindrical body 27, an open end 31 and a closed end29. Nozzle assembly 10 forms two distinct and separate spray patterns 15and 20 that are directed at divergent angles at first and secondinterior portions 26 and 28, respectively, of the container 25. Thus,first spray pattern 15 is directed at first interior portion 26 of thecontainer and second spray pattern 20 is directed at second interiorportion 28 of the container. As noted above, it is at these interiorareas 26 and 28 where more coating is desirable because the firstinterior portion 26 of the container is worked upon during the neckingoperation and the second interior portion 28 of the container is incontact with the pin tip of the pin chain during manufacture. The middlesidewall portion 33 normally has minimal contact and needs less coatingduring manufacture.

This invention decreases the amount of wasted coating liquid normallygenerated by the internal coating operation by minimizing misting andoverspray 18 as shown in FIG. 1. The orientation of nozzle assembly 10with respect to container 25 is such that with relative rotationalmovement of the container 25 and nozzle assembly 10, the entire bottomsurface of the container 25 is coated. In use, nozzle assembly 10 ispreferably arranged with respect to container 25 so that thelongitudinal axis 11 of the nozzle assembly 10 is disposed at an acuteangle "a" of approximately 28-31° relation to central longitudinal axis25a of the container 25 and about one-quarter inch distance from theopen end 31 of the container. This arrangement provides satisfactorycoating of the container bottom with commonly available airless nozzleinserts.

Nozzle 50 shown in FIGS. 2 and 3 comprises a generally cylindrical body52 having a forward portion 54, a rear portion 56, an intermediateportion 58 and nonparallel first and second passageways 70, 80 formed innozzle body 52. First conduit passageway 70 extends generallylongitudinally through the nozzle body 52 and terminates in a firstopening 72 disposed in the forward portion 54 of the nozzle. Likewise,second conduit passageway 80 extends generally longitudinally throughthe nozzle body 52 and terminates in a second opening 82 formed in theforward portion 54 of the nozzle. Conduits 70, 80 are each orientedwithin the nozzle body 52 at an acute angle "b" with respect to thecentral longitudinal axis 11 of the nozzle. Acute angle "b" ispreferably about 20° . Thus, the divergent arrangement of conduits 70,80 directs the separate spray patterns 15, 20 generally forward of thenozzle and in separate spray patterns diverging from the centrallongitudinal axis 11 of the nozzle.

First opening 72 is formed in a first planar surface 74 which issubstantially perpendicular to the central longitudinal axis 70a of thefirst conduit 70. Second opening 82 is formed in a second planar surface84 which is substantially perpendicular to a central longitudinal axis(not shown) of the second conduit 80. Planar surfaces 74 and 84 are eachdisposed at an acute angle "c" from horizontal. Angle "c" is preferablyabout 20° . Thus, the included angle between surfaces 74 and 84 is anobtuse angle of about 140° .

Intermediate portion 58 of nozzle body 52 is of generally cylindricalshape and rear portion 56 includes a circular shoulder portion 57 thathas a diameter greater than the diameter of the intermediate portion 58.Shoulder portion 57 is provided with a recessed cavity 57a formedtherein for connecting to a fluid-delivery line carrying the coatingfluid from a remote source.

Shown in FIG. 4 is an enlarged, isolated cross-sectional view of anencircled portion "X" of FIG. 2 containing conduit 70. While thedescription following herein is of the first conduit or passageway 70,said description is equally applicable to second conduit or passageway80 as said passageways are substantially identical. Conduit 70 is formedin nozzle body 52 as having a beveled portion 70b adjacent the forwardportion of the nozzle body, a small diameter cylindrical portion 70cadjacent the rear portion of the nozzle body, an enlarged diametercylindrical portion 70d juxtaposed to the beveled portion 70b and aninternally threaded portion 70e disposed between the large diametercylindrical portion 70d and small diameter cylindrical portion 70c.Internally threaded portion 70e is preferably defined by four millimetermetric threads.

As shown in FIG. 3, first and second openings 72, 82 are generallycircular in shape and are equally spaced on opposite sides of thecentral longitudinal axis of the nozzle body 52 along line 2--2.

Nozzle 50 of this invention is suited to threadably receive the nozzleinsert members 12, 14 (FIG. 1) within the passageways 70, 80,respectively, adjacent the forward portion 54 of the nozzle body 52.First passageway 70 and corresponding nozzle insert 12 direct the firstspray pattern 15 generally toward the first interior portion 26 of thecontainer, whereas second passageway 80 and corresponding insert member14 direct the second spray pattern 20 generally toward the secondinterior portion 28 of the container. Each nozzle insert 12, 14preferably includes an internal, hemispherical passage termination whichis cut through by an external, V-shaped groove to form an elongated,elliptical-like orifice. Coating liquid pumped under pressure throughthe nozzle insert is forced by the hemispherical termination of thepassageway to converge in its flow at and through the elongated orifice.Because of the converging flow at the orifice, the coating liquid isexpelled through the orifice into a planar, expanding, fan-like filmwhich breaks into spray particles which are carried by their momentum tointerior portions 26 and 28. Such nozzle inserts are of conventionaldesign so their structure and specific manner of operation are not shownor described herein in detail. Nozzle inserts suitable for use with thenozzle 50 of this invention are manufactured by Nordson Corporation.

The method and device provided by this preferred embodiment of theinvention may be further understood by reference to the followingexamples.

EXAMPLE ONE

Two internal coating lines were established to compare the dual orificenozzle assembly 10 provided by this invention to a conventional "drumhead," single orifice nozzle assembly. The dual orifice nozzle of thisinvention was coupled to an internal coating machine and was operatedcontinuously for about two and one-half days at 160-170 mg spray weightsusing an internal coating fluid manufactured by Glidden, Model No. 559IC coating. Overspray was captured by an overspray box. Sample testresults are shown below in Table One:

                  TABLE ONE                                                       ______________________________________                                               Average                                                                              Metal Exposure                                                                             Metal    Metal                                            Spray  Average 1st  Exposure Exposure                                         Wt. mg Pass After Necker                                                                          High     Low                                       ______________________________________                                        Dual orifice                                                                           167 mg   1.0 mA       2 mA   0 mA                                    nozzle                                                                        (35-can                                                                       sample)                                                                       Control cans                                                                           198 mg   .89 mA       2 mA   0 mA                                    (35-can                                                                       sample)                                                                       ______________________________________                                    

The overspray box coupled to the internal coating machine equipped withnozzle assembly 10 of the invention did not require changing over thetwo and one-half day period during which the internal coater wasoperated whereas the conventional coating machine using the standardsingle orifice nozzle assembly generally required changing once per12-hour shift. It is estimated that the dual orifice nozzle assembly ofthis invention reduced overspray by approximately 70 percent.

EXAMPLE TWO

A conventional spray gun equipped with the dual orifice nozzle assembly10 of this invention was set up on a coating line and continuouslyoperated in the 145-155 mg range. No metal exposure problems wereincurred. Tests were also conducted to compare overspray, film weightdistribution, and metal exposure with a standard internal coating set-upwhich employed a conventional single orifice drum head nozzlemanufactured by Nordson, Model No. 092-064, equipped with a turbulenceplate Model No. 027-309.

The two machines were operated approximately the same length of time andan overspray comparison was then made. The overspray boxes were emptiedon both machines and the time was recorded; and, after 12 hours, theoverspray boxes were again removed and weighed. The results are shownbelow in Table Two:

                  TABLE TWO                                                       ______________________________________                                                 Gun with  Gun with Dual Orifice                                               Conventional                                                                            Nozzle Assembly                                                     Single Nozzle                                                                           of this Invention                                          ______________________________________                                        Overspray weight                                                                         12      lbs.    4.5      lbs.                                      (12 hours)                                                                    Spray weight                                                                             151     mg      153      mg                                        avg.                                                                          ______________________________________                                    

A 50-can sample from each gun was then taken from the palletizer andchecked for metal exposure. The results are shown below in Table Three.

                  TABLE THREE                                                     ______________________________________                                                         Metal    Metal     Metal                                                      Exposure Exposure  Exposure                                         Spray Weight                                                                            Average  High      Low                                       ______________________________________                                        Coater with                                                                            151 mg      .45 mA   6 mA    0 mA                                    Conventional                                                                  Single Nozzle                                                                 (Control)                                                                     Coater with                                                                            153 mg      .40 mA   4 mA    0 mA                                    Dual Orifice                                                                  Nozzle of this                                                                Invention                                                                     ______________________________________                                    

Further, the film weight distribution was then checked from the twomachines with a strand gauge. FIG. 5A depicts a conventional "206" gaugealuminum container 25 and FIG. 5B illustrates the film thicknessdistribution of the coating liquid sprayed on the interior of the canmeasured at spaced points along the inside surface of the container body27. As shown in FIG. 5A, the measurements were taken at points "d", "e","f" and "g" which were at distances of 4.00 inches, 2.875 inches, 1.75inches and 0.25 inches, respectively, measured from open end 31 of thecontainer. The results of the gauge readings are illustrated in FIG. 5Bin which milligrams per square inch of coating liquid is measured on thevertical axis and the distances d1, d2, d3 and d4 from whichmeasurements at d, e, f and g, respectively, were taken are shown on thehorizontal axis. The smallest measurement occurs at point "f" whichgenerally corresponds to the middle portion 33 of the container wall asshown in FIG. 1. Measurements taken at points "d" and "e" generallycorrespond to the second interior portion 28 at which second spraypattern 20 is directed as shown in FIG. 1; and the measurements taken atpoint g generally correspond to the first interior portion 26 at whichfirst spray pattern 15 is directed. Thus, the nozzle and method of thisinvention directs the internal coating liquid more efficiently where itis required most inside the can at interior portions 26, 28. While thestrand gauge was not calibrated, the resulting values are useful forrelative comparison. The readings represented in FIG. 5B were averagereadings taken from five can samples.

Lastly, the spray weights on the conventional control coater and thecoater equipped with the dual orifice nozzle assembly of this inventionwere increased to 180-185 mg and checked for blistering. The dualorifice nozzle set-up did not blister at this weight whereas theconventional set-up produced moderate blistering.

An alternative preferred embodiment of this invention is shown and willnow be discussed in reference to FIGS. 6-9, wherein like referencenumerals correspond to like components. Referring now to FIG. 6, anozzle assembly 110, which is intended to be arranged adjacent acontainer 125 as it is transported along in the manufacture process,includes a spray nozzle 150 carrying nozzle inserts 112 and 14.Container 125 has a generally cylindrical body 127, a closed end 129, abottom wall 129a, an open end 130 and a sidewall 131. Nozzle assembly110 is adapted to form two distinct and separate spray patterns 115 and120 that are directed at divergent angles at first and second interiorportions 122 and 124, respectively, of the container 125. First interiorportion 122 preferably includes the entire length of sidewall 131 and aportion of the crown of bottom wall 129a of closed end 129. Secondinterior portion 124 preferably includes the middle portion 133 and thebottom portion 128 of sidewall 131. Thus, first spray pattern 115 isdirected at first interior portion 122 of the container and second spraypattern 120 is directed at second interior portion 124 of the container.

This arrangement directs more coating liquid at the bottom portion 128of sidewall 131, which is an area where more coating is desirablebecause the bottom portion 128 is in contact with the pin tip of the pinchain during manufacture. This invention decreases the amount of wastedcoating liquid normally generated by an internal coating operation byminimizing misting and overspray referenced 118 in FIG. 6. Theorientation of nozzle assembly 110 with respect to container 125 is suchthat with relative rotational movement of the container 125 and nozzleassembly 110, the entire interior surface of the container 125 issufficiently coated.

In use, nozzle assembly 110 is preferably arranged offset laterally withrespect to a central axis 125a of container 125 and so that thelongitudinal axis 111 of nozzle assembly 110 is disposed at an acuteangle a' of approximately 3-5 degrees in relation to a verticalreference line 113, which is parallel to central longitudinal axis 125aand about one-half inch distance from the open end 130 of container 125.As shown in FIG. 6, nozzle assembly 110 is preferably offset laterallyto one side of axis 125a a distance of approximately one-quarter inch(0.25 in.), as compared to the arrangement of FIG. I wherein nozzleassembly 10 is disposed centrally of the central axis 25a. Thisarrangement provides satisfactory coating of the interior of a containerwith commonly available airless nozzle inserts.

Nozzle 150 shown in FIGS. 7 and 8 comprises a generally cylindrical body152 having a forward portion 154, a rear portion 156, an intermediateportion 158 and nonparallel first and second conduit passageways 170 and180, respectively, formed in nozzle body 152. First conduit passageway170 extends generally longitudinally through the nozzle body 152terminating in a first opening 172 disposed in the forward portion 154and is oriented within nozzle body 152 so that its central longitudinalaxis 170a is parallel to the central axis 111 of the nozzle body 152.Second conduit passageway 180 extends generally longitudinally throughthe nozzle body 152 terminating in a second opening 182 disposed in theforward portion 154 and is oriented within the nozzle body 152 at anacute angle c' with respect to vertical. Acute angle c' is preferablyabout 61-64 degrees, and most preferably, about 62.5 degrees. Thus, thedivergent arrangement of conduits 170 and 180 directs the separate spraypatterns 115 and 120 generally forward of the nozzle and in separatediverging spray patterns.

First opening 172 is formed in a first planar surface 174 which issubstantially perpendicular to the central longitudinal axis 170a of thefirst conduit passageway 170. Second opening 182 is formed in a secondplanar surface 184 which is substantially perpendicular to a centrallongitudinal axis 180a of the second conduit passageway 180. Thus, firstplanar surface 174 is disposed substantially horizontally and therebysubstantially perpendicular to central longitudinal axis 111, whilesecond planar surface 184 is disposed at a preferred acute angle c' fromhorizontal and first planar surface 174 of approximately 26-29 degrees,most preferably about 27.5 degrees. The included angle between first andsecond planar surfaces 174 and 184 is therefore an obtuse angle ofapproximately 151-154 degrees, most preferably about 152.50 degrees.

Intermediate portion 158 of nozzle body 152 has a generally cylindricalshape with opposing milled flat sides 158a (FIG. 8) suitable foraccepting an appropriately sized wrench or tool. Rear portion 156includes a circular shoulder portion 157 that has a diameter greaterthan the diameter of the intermediate portion 158. Shoulder portion 157is provided with a recessed cavity 157a formed therein for connecting toa fluid-delivery line carrying the coating fluid from a remote source.

Shown in FIG. 9 is an enlarged, isolated cross-sectional view of anencircled portion "X" of FIG. 7 containing first conduit passageway 170.While the following description is of the first passageway 170, thedescription is equally applicable to second conduit passageway 180 assaid passageways, while they are oriented differently with respect tothe central longitudinal axis 111 within nozzle body 152, aresubstantially identical in structure. First conduit passageway 170 isformed in nozzle body 152 as having a beveled portion 170b ofapproximately 0.020 inches and 41 degrees adjacent the forward portion154 of the nozzle body 152, a small diameter cylindrical portion 170cadjacent the rear portion 156 of the nozzle body 152, an enlargeddiameter cylindrical portion 170d juxtaposed to the beveled portion170b, and an internally threaded portion 170e disposed between the largediameter cylindrical portion 170d and small diameter cylindrical portion170c. Internally threaded portion 170e is preferably defined by fourmillimeter metric threads. As may be seen from comparing the passageways70 and 170 shown in FIGS. 4 and 9, respectively, said passageways aresubstantially identical in structure, while their specific dimensionsmay differ slightly.

As shown in FIG. 8, first and second openings 172 and 182 are generallycircular in shape arranged along a diameter of the generally cylindricalnozzle body 152, which diameter coincides with plane 7--7, and arespaced unequal distances on opposite sides of the central longitudinalaxis 111 and a central latitudinal axis 111' of the nozzle body 152.First opening 172 is disposed a closer distance to central latitudinalaxis 111' than is second opening 182, and a boundary 178 between firstplanar surface 174 and second planar surface 184 lies beyond latitudinalaxis 111', the distance of which is referenced d26 in FIG. 7.

Nozzle body 152 of this invention is suited to threadably receive thenozzle insert members 112 and 14 (FIG. 6) within the passageways 170 and180, respectively, adjacent the forward portion 154 of the nozzle body152. First conduit passageway 170 and corresponding nozzle insert 112direct the first spray pattern 115 generally toward the first interiorportion 122 of the container, and second conduit passageway 180 andcorresponding insert member 14 direct the second spray pattern 120generally toward the second interior portion 124 of the container.

Nozzle insert member 14 is employable with both embodiments of the spraynozzle as shown in FIGS. 1 and 7. Nozzle insert member 112 is verysimilar in construction to nozzle insert members 12 and 14 in that itpreferably includes an internal, hemispherical passage termination whichis cut through by an external, V-shaped groove to form an elongated,elliptical-like orifice. Coating liquid pumped under pressure throughthe nozzle inserts is forced by the hemispherical termination of thepassageway to converge in its flow at and through the elongated orifice.Because of the converging flow at the orifice, the coating liquid isexpelled through the orifice into a planar, expanding, fan-like filmwhich breaks into spray particles which are carried by their momentum tointerior portions 122 and 124. As shown in FIG. 6, nozzle insert 112preferably provides a wider spray pattern and, thus, a higher flow ratethan nozzle insert 14. Nozzle inserts suitable for use with the nozzles50 and 150 of this invention are manufactured by Nordson Corporation.Such nozzle inserts are of conventional design so their structure andspecific manner of operation are not shown or described herein indetail.

The method and device provided by the alternatively preferred embodimentof the invention may be further understood by reference to the followingexample.

EXAMPLE THREE

Production testing of the alternatively preferred embodiment of thespray nozzle device provided by this invention was conducted to comparethe performance of the alternative embodiment, that is, the dual-orificespray nozzle having a first passageway arranged parallel to the centralaxis of the nozzle and a second passageway arranged at an acute angle inrelation to the central axis, to a conventional spray gun set up, i.e.,single-orifice spray nozzle. The tests were focused primarily on theextent of aluminum pick-up in the beverage liquid stored in the can atpredetermined intervals. The extent of aluminum present in the beverageis generally inversely proportional to the sufficiency of the internalcoating applied to the containers.

Once the containers making up the test group were internally coated,provided with end closures and filled with a beverage, Pepsi Cola® inthis instance, the containers of a first study group were stored in anangled upright position (15 degrees) and the containers of a secondstudy group were stored in an inverted position (upside down). The canswere internally coating with a coating liquid available from GliddenCorporation, grade no. 640-C-554. Selected cans from each study groupwere then pulled at initial, 30, 60, 90, 120 and 180 day intervals todetermine the amount of aluminum in the liquid beverage measured asparts per million (ppm). The aluminum content was determined by atomicabsorption spectroscopy. A common maximum allowance for this test, forexample, is 2.5 ppm for 90 days.

Generally, the test results indicated that the amount of aluminumpresent in the beverage stored in containers internally coated by thealternatively preferred nozzle assembly and method of this invention wasapproximately two-thirds less than that of the cans coated byconventional internal coating methods. More particularly, the 120-daytest showed the inverted cans increasing in aluminum content while theupright cans had lesser increases in aluminum content.

In the manufacture of the nozzle devices of this invention, Type 303 or304 stainless steel is preferred. In addition, the dimensions referredto in the figures and listed below in Table Four are preferred:

                  TABLE FOUR                                                      ______________________________________                                        Dimensions                                                                              Value (inches) Angles   Degree                                      ______________________________________                                        d5        0.0337         a        28-31                                       d6        0.1250         b        20                                          d7        0.3125         c        20                                          d8        0.0500         d (bevel)                                                                              41                                          d9        0.0970         a'       3-5                                         d10       0.4900         c'         62.5                                      d11       0.5900                                                              d12       0.2000                                                              d13       0.0750                                                              d14       0.0200                                                              d15       0.1590                                                              d16       0.0520                                                              d17       0.2310                                                              d18       0.1000                                                              d19       0.5900                                                              d20       0.3130                                                              d20'      0.1385                                                              d21       0.0400                                                              d22       0.1290                                                              d23       0.1000                                                              d24       0.2220                                                              d26       0.2930                                                              d28       0.3750                                                              d29       0.1875                                                              d30       0.1590                                                              d31       0.2000                                                              d32       0.0520                                                              d33       0.0910                                                              d34       0.0770                                                              ______________________________________                                    

Thus, the dual orifice nozzles 50 and 150, nozzle assemblies 10 and 110and the methods of operation provided by this invention deposit theinternal coating liquid more efficiently where it is most requiredinside the can; reduce overspray by directing two separate, small,defined spray patterns at the desired interior portions of the can;reduce overspray by also decreasing the misting of the nozzle, andreduce the likelihood of blistering. In addition, the invention allowsfor the use of lower operating spray weights without compromising sprayquality and blistering, which is a common problem with higher sprayweights. These features, among others, reduce the amount of internalcoating liquid required in such operations, as well as reducing manhours spent on cleaning the coating machines.

While what has been described constitutes a presently most preferredembodiment, the invention can take many other forms. Accordingly, itshould be understood that the invention is to be limited only insofar asis required by the scope of the prior art and of the following claims.

I claim:
 1. A method of applying an effective nonuniform coating withina container having a generally cylindrical shaped sidewall, an open endand a closed end defined by a bottom wall, said method comprising thesteps of:delivering a flow of coating material to single nozzle meansfor coating the interior of the container; dividing the coating materialflow within the single nozzle means into a first flow portion and asecond flow portion having separate diverging patterns with maintaineddirections with respect to each other; directing the first flow portionso its separate diverging pattern intersects a first interior portion ofthe container while directing the second flow portion so its separatediverging pattern intersects a second interior portion of the container;and providing relative rotation between said container and said firstand second flows of coating material, said first and second flows ofcoating material applying a coating nonuniformly onto the first andsecond interior portions of the container.
 2. A method of internallycoating a container having a generally cylindrically shaped sidewall, anopen end and a closed end defined by a bottom wall, said methodcomprising the steps of:delivering a flow of coating liquid to a singlenozzle means; providing the single nozzle means and the container withrelative rotation; dividing the coating liquid flow into a firstdistinct flow portion and a second distinct flow portion within thesingle nozzle means; directing the first distinct flow portion generallytoward a first interior portion of the container and directing thesecond distinct flow portion generally toward a second interior portionof the container, said first and second distinct flow portions beingdirected at said first and second interior portions in separatediverging patterns forward of the single nozzle means; and directing acoating of greater thickness onto the sidewall of said containeradjacent the closed end thereof, said first interior portion includingthe sidewall and a portion of the bottom wall of the container and saidsecond interior portion including a portion of the opposing sidewalladjacent the closed end of said container.
 3. The internal coatingmethod as in claim 2 including the step of directing the first andsecond flow portions in separate diverging patterns at an angle of about26-29 degrees with respect to one another.
 4. The internal coatingmethod as in claim 2 wherein said step of directing the flow portions inseparate diverging patterns includes directing the first flow patternalong a central spray axis forwardly of the single nozzle means andsubstantially parallel with a central longitudinal axis of the singlenozzle means, and directing the second flow pattern in an angleddirection forwardly of the single nozzle means along a central sprayaxis lying at an acute angle with respect to the central longitudinalaxis of said single nozzle means.
 5. The internal spraying method as inclaim 4 including the step of arranging the central longitudinal axis ofthe single nozzle means offset laterally from and at an included acuteangle of about 3-5 degrees with respect to the longitudinal central axisof the container being coated.
 6. The internal coating method as inclaim 2 wherein the single nozzle means comprises:a body having aforward portion, a middle portion, a rear portion, a first conduitextending generally longitudinally therethrough terminating in a firstopening disposed in the forward portion, and a second conduit extendinggenerally longitudinally therethrough terminating in a second openingformed in the forward portion, said first opening being oriented in aplane disposed normally to the central longitudinal axis of the singlenozzle means to direct the first flow portion of the coating liquid in afirst distinct pattern, said second opening being oriented in a planedisposed at an acute angle of about 26-29 degrees with respect to thecentral longitudinal axis of the single nozzle means to direct thesecond flow portion of the coating liquid in a second distinct pattern.7. The internal coating method as in claim 6 wherein said single nozzlemeans further comprises:a first nozzle insert member positioned with thefirst conduit adjacent to the forward portion for directing the firstspray pattern generally toward the first interior portion of thecontainer; and a second nozzle insert member positioned within thesecond conduit adjacent to the forward portion or directing the secondspray pattern generally toward the second interior portion of thecontainer.
 8. The internal coating method as in claim 7 wherein thefirst and second nozzle insert members are generally cylindrical andhave an externally threaded portion, and wherein the first and secondconduits each have internally threaded portions to threadably receivetherein the first and second nozzle insert members, respectively,adjacent to the forward portion of the nozzle means.
 9. The internalcoating method as in claim 2 wherein the first and second flow portionsand separate diverging patterns are formed without the use of compressedair by first and second airless nozzle insert members carried by saidsingle nozzle means.
 10. A method of applying an effective non-uniformcoating within a container having a generally cylindrical shapedsidewall, an open end and a closed end defined by a bottom wall, suchmethod comprising the steps of:delivering a flow of coating material toa single applicator having a pair of orifices for coating the interiorof the container; dividing the coating material flow within the singleapplicator into a first flow portion and a second flow portion havingseparate diverging patterns with maintained directions with respect toeach other; directing the first flow portion with a first orifice ofsaid pair of orifices so its separate diverging pattern intersects thesidewall and a portion of the bottom wall while directing the secondflow portion with a second orifice of said pair of orifices so itsseparate diverging pattern intersects a portion of the sidewall adjacentto the closed end of said container; and providing relative rotationbetween said container, said applicator and said first and second flowsof coating material, said first and second flows of coating materialapplying a coating of greater thickness onto the sidewall of thecontainer adjacent the closed end thereof.